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“Blue Light” creating capacity for nothing (2007)

theoryofconstraints.blogspot.com

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Re: “Blue Light” creating capacity for nothing (2007)

#62

The article's story anecdote of "blue light" is about finding the true value in a process. Blue light means the welder is actually creating value in the product. Anything else in the process does not help build value to the product. It is all non-value added activities. The non-value added activities might be necessary such as setup, delivery, reposition or what not but it doesn't drive value. By maximizing the blue…

> Blue light means the welder is actually creating value in the product. Anything else in the process does not help build value to the product.

So when the downturn comes, fire the trade assistant.

Re: “Blue Light” creating capacity for nothing (2007)

#63

Earlier quoted context omitted.

That's a good point, but then, what does said junior dev accomplish with those slides, that they couldn't do without them? It's not like slides are improving communications much (some would say they're hindering it[0]), not relative to e.g. sketches on a flip chart. I think this is another example of a problem I'm hinting at: the reason said junior dev has to make slides is because they can . If their only option was…

On the point that not every presentation needs a deck, I completely agree with you. So if an individual is abusing slides (or another tool) "just because" - that's bad but perhaps a different problem than what we started to talk about. On the flip side, I've occasionally been really impressed by the quality of decks I've seen from developers. Not talking about looks-wise (that helps but especially not holding devs to…

I agree with the flip side point. I like to occasionally make a slide deck myself, or do little bit of computer graphics or audio processing, and I appreciate having the capability at my disposal.

But my point is slightly different. It's not that today, more people have cars, but are much more likely to drive themselves to a stupid place. It's that cars - particularly in the United States - very quickly stopped being a tool that empowers the owner, and became a necessity that's required to interact with the society: with cars being accessible enough, architecture and businesses evolved to compensate. For many, this just means they're forced to endure hours of traffic every day. Is this better than before cars were ubiquitous?

Also, the dream of self-driving cars isn't motivated just by the safety argument, but as much - if not more - because a self-driving car is a chauffeur for the masses. It won't let you skip the traffic, but at least it won't be a complete waste of life.

Another example: every self-service website or app - ticket purchase, food ordering, government form - is replacing what used to be a human interaction. In person, over the phone, or (for a brief period of time) over e-mail. This has some benefits, but one major loss is that you're now limited to a dumb (and often broken) form streamlined for machine processing, where previously you'd be interfacing with a person - so good luck if something breaks, or you have some custom need. Plus, self-service sites very quickly become time-negative: with a person on a phone, you can describe what you need in high-level terms. You don't have to search, explore, read FAQs, and type so much stuff.

What makes this into a problem is that you don't have a choice here - self-service systems are cheaper, they justify cutting human-level support to minimum. Most companies still offer you a phone number to call, but instead of quickly reaching a competent human, you're forced to endure an automated system designed to tire you out, increasingly often featuring a broken "AI" voice assistant, that is only ever good at one thing: keeping you from reaching a human. And then, half the time, the human consultant can't do anything because "the computer says 'no'".

(Note how the same companies that make you suffer through an hour of Muzak and "smart" "AI" "assistant" when you call them, will then have a nice, pleasant, real human cold-call you, to upsell you something that's usually a bad deal for you. It's clear what's driving all those "helpful" technologies: company operating expenses.)

And over the past few years, and particularly in the past few weeks (i.e. since ChatGPT was released), people talk so much about using language model AIs to interface with services and technology - mostly without realizing that what they're asking for is a cheaper, inferior form of having a person on the other end of a phone/chat.

Re: “Blue Light” creating capacity for nothing (2007)

#64

I know most people are gushing with positives ... but to me this reads like the epitome of a clueless consultant who got lucky because the 30 plus years manager missed the basics ... unless the era of the tale was early 60s or something or some middle of nowhere fabrication that sprang up with little idea of how other similar places work ... um great story but what really was this based on. In the industry it's fairl…

To be fair, the situation in the story truly does happen in a variety of jobs and businesses. What you are highlighting is the countervailing lesson, kind of a specialization of Chesterton's fence: if highly experienced people are doing a process in what seems to be an inefficient manner, consider that it might actually be the most efficient manner, given constraints that you do not fully understand or are not aware…

I'd agree this sort of thing does happen in regular life where the agent of change is someone who's had wide ranging experience and maybe a lateral thinker and adopting other work processes that are proven in existing industries. (However the story above is just that, the chance that happened as stated are slim ... and only for reasons along the lines I've mentioned being a bit isolated or operating in a vacuum.)

Sometimes, not that I can think of much software or hardware related situations, the fence is just an idea, years of experience have lead to a situation where they've established a comfort zone of sorts, and hesitant to change the way things are done ... often because they don't totally understand complicated processes they might be using ... or because things done differently might be more open (but rare) to a specific problem or being prone to a failure which from their previous experience, might have chewed up half a day to a day if not more to sort it out ... when the fix by someone who is competent (having been shown the correct way from the start) is able to resolve the issue quickly, barely 20 minutes of time and patience and it's in half an hour it's like nothing happened.

As for "do not fully understand" - yes that is an excellent way to describe total inadequacy.

Re: “Blue Light” creating capacity for nothing (2007)

#65
post #19

It's incredible that one person was able to handle all the work that took up 90% of the welders time. Lots of time must have been spent getting in and out of gear. I’d expect that one guy to end up the bottleneck and the welders to be waiting for him to bring them parts, but it says he even as time to peel the plastic! I imagine the blue light applied to programming would be a crude tool. I want to hear keys clacking…

Not all of it, just enough of it to move the bottleneck somewhere else. A factory is always bottlenecked by something, sales if nothing else

> A factory is always bottlenecked by something, sales if nothing else

I don't feel like that's a very good conclusion.

If a good chunk of your processes have roughly the same capacity, and they're all running at that capacity, you don't have anything I would call a bottleneck.

Re: “Blue Light” creating capacity for nothing (2007)

#66
post #26

It's incredible that one person was able to handle all the work that took up 90% of the welders time. Lots of time must have been spent getting in and out of gear. I’d expect that one guy to end up the bottleneck and the welders to be waiting for him to bring them parts, but it says he even as time to peel the plastic! I imagine the blue light applied to programming would be a crude tool. I want to hear keys clacking…

So the derivation of Eli Goldratt’s ideas for programming is necessarily different because we are doing artisanal work rather than manufacturing. But yes taken naively it is a measure of Git commits merged into the main branch after running precommit checks and tests and code review and whatever else, and ideally shipping to prod directly. And this is where you want to enable the ability to ship broken code without b…

That sounds like an extremely efficient way to get one feature, or a series of overly dependent features, done as fast as possible. But I'm not understanding why that would be your goal except in rare circumstances.

Why not have most of the team coding toward the goals and one or two helpers? Especially because that's how the welding story worked.

Re: “Blue Light” creating capacity for nothing (2007)

#67

Bullshit story the consultant made up to bolster his point (93% efficiency claim from a foreman wtf). Of course finding some help moving parts around for the welders would be the first thing the foreman would think of, because thats what foremans do all the time in factories. Maybe the welders chose to work this way (i.e. inefficiently) because continuous welding produces fatigue which risks H&S and lowers the qualit…

That literally is the solution they landed on: they hired helpers, i.e. extra personnel. The critical difference is that they did not need to hire more welders, buy more welding equipment, set up more welding stations. I don't care if the story came right out of Aesop's fables, because it's a good story and it makes a good point.

The problem is it's not really a good story to tell, because this leads people, who might not know any better, to later in life recount to some welder friend(s) they happen to know, about how the article's creator was the guy who worked out welders needed TAs ... or one fabrication welding business needed TAs. It's better not to make things up, or use really really incredulous examples, that may lead people to unwittingly embarrass themselves.

It's almost like a story where the genius works out the boss needs a secretary.

When it comes to inventing stuff, important points are often overlooked.

Imagine if the same sort of story recounted a company with a 9 to 5 office where 100 people worked solely at their desktop computer station back in the days of W98 or XP doing whatever it was they did. The guy observes when people arrive for work they're not productive because the first five minutes their system was booting and virus checking. There's over 8 hours of lost production so it's worthwhile to hire an additional low paid casual worker for minimum award, with the minimum required hours for casual (here it's iirc it's been around four hours a day,) to arrive a couple hours beforehand to ensure all systems are running so workers can start working immediately when they walk through the door. Clearly that sounds right, but most here would know, in practice, for many workers, output would not increase substantially. The nuance is in the finer details.

Re: “Blue Light” creating capacity for nothing (2007)

#68

Earlier quoted context omitted.

Like a VC for instance. They are blood sucking leeches upon our society

Like I try not to get hung up on language but "value/productivity" and "leeches" are essentially antonyms.

I don’t see the contradiction?

“Value/productivity bigot” = what they think

“Leeches” = what they are

Re: “Blue Light” creating capacity for nothing (2007)

#69

It's incredible that one person was able to handle all the work that took up 90% of the welders time. Lots of time must have been spent getting in and out of gear. I’d expect that one guy to end up the bottleneck and the welders to be waiting for him to bring them parts, but it says he even as time to peel the plastic! I imagine the blue light applied to programming would be a crude tool. I want to hear keys clacking…

He’s not taking welding gear off and then re-donning it 50 times a day, for starters.

Re: “Blue Light” creating capacity for nothing (2007)

#70

Bullshit story the consultant made up to bolster his point (93% efficiency claim from a foreman wtf). Of course finding some help moving parts around for the welders would be the first thing the foreman would think of, because thats what foremans do all the time in factories. Maybe the welders chose to work this way (i.e. inefficiently) because continuous welding produces fatigue which risks H&S and lowers the qualit…

The story might not be a accurate, but the concept is certainly valid. I see this sort of thing all the time. This terrific story helps people to understand the core point, that busy does not equal productive.
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